Multilayered fibrous batting



Nov. 16, 1948. R. r. HLAVATY HU'LTILAYERED FIBROUS BTTING 2 Sheets-Sheet1 Original Filed Sept. 29. 1941 Nwm.

Nov. 16, 1948.l R. F'. HLAvA'rY 2,454,175

' HULTILAYERED Imanous annuo v original Filed sept. 29, 1941 2sheets-Shasta Patented Nov. 16, 1948 MULTILAAYERED FYIB'ROUS BATTINGRudolph F. Blavaty, Cicero, Ill.

Original appiioation september 29.1941, snm l No. 412,815. Divided andthis ippllcation April l 7, 1945, SellliNn. l587.042'

This invention relates to a multi-layer article' i and to a method ofmaking the same. It has for one object to provide a batt characterizedby the arrangementof the parts of which it is made. this arrangementbeing such as to -increase the strength as compared to batts of presentmanufacture.

It .has for another object to provide a b att or layer of the typeindicated. which may be formed oi' sheet material or fibrousmaterial ormixtures including sheets, loose hbrous material, powdered material,liquid material, fluid material or any oi' the materials mentioned,separately or in any combination.

Another object is to provide a batt or layer of the type indicated inwhich synthetic fibers or strands are used. In any of the battsindicated I might use any of the materials mentioned. Where iibrousmaterial is used. the fibers may be cf any nature, such as vegetable.animal, mineral. metallic or synthetic, as stated. Adhesives, cements orglues of any nature may also be used.

Another object is to provide means for forming a composite article whichmay be formed of batts or layers of the type indicated above or may beformed of standard or well-known types of batts or layers. An object ofthat form of the invention is to provide' a member formed of a pluralityof batts or layers of generally identical construction and to arrangesome of the batts in a manner different from the other batts.

Another object of this form of the invention is to provide a compositearticle formed of a plurality of batts in whicha batt is arrangedgenerally longitudinally of the totalv article and in which one or moreadditional batts may be Claiml. (Cl. 154-54) In general, the battisformed mieu in my'patent No. '2,423,709, med september 29, 1941, andvissued October 7. 1947. The

batt might possibly be made of other sorts of `lappers and a standard*orconventional lapper might be modified by the addition of controlssuitable for producing the batt shown". The batt might even be made byhand.

of a plurality oi' layers of material. This material is laid backand'iorth so that a number oi layers are superimposed upon each other.Ii' a substantial quantity of the material is to be made, which is oftenthe case, the batt as it is built up is moved in one direction. whilethe web of which it is formed is continually laid'transversely. The battillustrated in Figure 1 is produced as-a part of such a continuousprocess in which the finished batt is carried away toward the left,while' the web' continues to be moved back and forth and dep'os--ited-progressively upon thebatt as it builds up.

The batt is formed of superimposed layers of v a web A. As the web isdeposited to form the batt and is fed transversely, it is arranged sothat the material of which it is formed is deposited in a series ofzones which are disposed at an angle to each other. Thus the topmostlayer B of the web is arranged in a series oi' angularly arrangedtransversely of the compositev article by folding or otherwise. Sheetmaterial of any nature may be laid down -ln the manner describedherewith in connection with the batts or layers, and reinforcing may beincluded in the sheets, the batts. the layers or otherwise. Y

Other objcts will appear from time to` time throughout the specificationand claims.

T his invention is illustrated more or less diagrammatically in theaccompanying drawings, wherein:

Figure 1 is a plan view of the batt of this invention; f

Figure 2 illustrates-a modifiedv form of batt;

Figure 3 'is a side elevation of one form of the composite article;

Figure 4 is a side elevation of a modified form of the compositearticle; and

Figure 5 is a side elevation of a further modified form.

Like parts are indicated by like characters throughout the specificationand the drawings.

The batt as shown in Figure 1 will ordinarily be made on a lapper.' Onesuch lapper is illusdisposed zones I. 2. 3, 4, and 5. The particular`form of batt illustrated may be considered as formed of fibrousmaterial loosely arranged' and compacted. For example. a web of hair.cotton or any natural or vegetable or synthetic or other fibrous orstranded material may be used. It will be convenient to describe thematerial as fibrous vin the first instance and to describe it otherwiselater.

As shown, the fibers are indicated diagrammatically as lying more orvless in a uniform manner across the zones in which they are deposited.'I he fibers of zone i are at an angle to the fibers of zone 2 and thefibers of zone 3 are at an angle to the fibers of zones 2 and 4. Asshown, the fibers of each zone are approximately at right angles 4to thefibers vof an adjacent zone. but almost any angular relationship mightbe used, and it may be varied throughout a batt. and many differentrelationships might beused in a single batt. It is not intended tosuggest that` In general, they arranged at an angle to the fibers ofcorresponding zones of layers -above and below. Thus in the second layerC, as shown in Figure 1, the fibers are arranged in zones 6, 1,8, 9, I0,II, I2, I3 and I4 within the layer C, and the fibers of each zone are atan angle to the fibers of adl'acent zones in the same layer and thefibers of each zone of the layer C are also at an angle to the fibers ofcorresponding zones in the layers above and below them. The fibers ofzone 'I cross or intersect the fibers of zone 4. AThe same is truethroughout the other zones.

It will not be necessary to renumber and redelscribe the layers belowlayer C. As shown, five layers appear in one part of the batt and fourin the other. The above description, however, makes it clear that ineach layer the fibers .are preferably arranged in zones disposed 'at anangle to each other and that the layers are superimposed on each otherin such manner that the fibers of each zone of each layer are at anangle to the fibers of -corresponding zones above and below them.

In the modified form of Figure 2 a batt is shown in which some layershave the-ir fibers arranged in the angularly disposed zones abovementioned and in which other layers are formed without this angular andzone arrangement of fibers. Thus lthe uppermost layer D of Figure 2 hasits fibers arranged in zones I5, I6, II, I8 and I9. The next llayer E-does not have fibers arranged in angular-ly disposed zones, and thethird layer F has fibers arranged in angularly disposed zones 2Il, 2|,22, 23, 24, 25,26, 21 and 28. The remaining layers of the batt aresimilarly arranged and need not be redescribed.

I have spoken above of a fibrous web and fibrous layers and have saidthat the 'fibers which form this web may be loosely compacted. A battcorresponding to 4that shown could be formed of more closely joinedfibers. A batt might be formed of layers of paper or woven fabric of anymaterial. It might be formed of amixture of fibrous material or strandedm at e ri al, together with powdered material or together with powderedmaterial and adhesive material. A composi-te article might be built upof powdered material and adhesive material alone Ain which successivelayers would be deposited to form a composite article and in which oneormore of the successive layers would be divided into zones angularlydisposed with respect to each other. The invention, therefore, embodiesbroadly the idea of a composite article f-ormed of successive layers ofmaterial of almost any nature superimposed upon each other and in whichsome or all of the layers are formed of zones angular-ly disposed withrespect 'to each other. Preferably, also, the successive layers are soarranged with respect to each other that the zones of one layer areangularly disposed with respect to the corresponding zones of layersabove and below them.

Experience has shown that such an arrangement of materials produces amuch stronger batt or composite article than one which can be producedif the layers are merely superimposed upon each other without theaddition of the angularly disposed zone arrangement.

Where I have used the word batt it is -to be taken generally as meaningIa composite article formed of superimposed masses or layers ofmaterial. Its meaning is not limited to its narrower use in the textilearts, and as applied herewith it refers to an article which may be soft,flexible and compressible or may be substantially hard, rigid andrelatively non-compressible. The batt 0r layer referred to throughoutthe specification might be, as above mentioned, of any material. Itmight be formed of rubber or a synthetic-rubber sheet, as well vas ofthe synthetic, plastic, fibrous materials referred to, and it mayinclude clafy, asbestos. silica, ceramic material and any other suitablematerial. In general, this invention contemplates the use of anymaterials which can be arranged generally as shown in Figures 1 and 2.

The structure `shown in Figures 3, 4 and 5 may be made of `almost anymaterial and may be made of batts such as those shown In Figures l or 2.They may also be made of batts of any other nature. Since the batt ofFigures 1 and 2 and the A articles of Figures 3, 4 and 5 lend themselves.to

use as insulation material, they may be made of relatively light,flexible and compressible material, but the invention Is not limited tomaterial of that nature.

The device of Figure 3 is formed of two relatively plane layers or batts29 and 30. Between these is positioned a folded layer or batt 3l. Asshown, this layer is produced by forming folds within a relatively longlayer or batt and the batt, when so folded, is positioned between thelayers 29 and 30. Preferably the three layers are secured together byadhesive material, or otherwise.

The composite article of Figure 4 includes four layers of materialabottom relatively plane layer 32 and an upper relatively plane layer 33;between these layers .there are positioned .two layers 34 and 35. The-seare generallysimilar to the layer 3| of Figure 3 and lpreferably consistof substantial lengths of unbroken material, this material being in eachlength folded upon itself to produce the form shown in Figure 4. Theseveral layers of the form of that figure may be secured to gether byadhesives, binders or otherwise.

In the form of Figu-re 5 five layers are used--a bottom layer 36, anintermediate layer 31 and a top layer '38 are preferably relativelyplane, and between each pair of these layers is positioned a foldedlayer 39 and 40. yThese layers are generally similar `to the layers 3I,34 and 35. y

In the devices of Figures il,v 4 and 5 the several layers or batts arepreferably secured together. Adhesives or mechanical fastening means maybe used. In the description of Figures 3, 4 and 5 where the word layerhas been used, it is to be taken as referring to aunit such as themembers 29, 39 or 3l. It is to be remembered that these layers maythemselves be formed of a batt such as that shown in Figures 1 and 2. Inthe description of the last three figures the word layer refers to anentire batt or its equivalent, while in the description of Figures land2 the Word layer has been used to describe a part of a batt. v

The devices of the last three figures may be formed of fibrous materialor non-fibrous material or mixtures of any such materials. Ordinarilythe folded layers, at least, will be made `of relatively soft material.They may be made of material which is initially soft enough to permitfolding but later becomes more rigid or harder.

disposed in a plurality of generally parallel zones,

the fibers of the material of each such zone being y disposed at anangle to the fibers of the material of adjacent zones of said layer, andthe fibers of the material of each zone of an intermediate layer beingdisposed at an angle to the fibers of the material of correspondingzones of layers above and below it.

2. In combination in a multi-layer article, a plurality of superimposedlayers of fibrous material, the fibers of each layer of fibrous materialbeing disposed in a plurality of zones extending generallylongitudinally of said layer, the fibers of the material of eachsuchzone in any one layer being disposed at an angle to the fibers ofthe material of adjacent zones of said, layer, and the fibers of thematerial of each zone in an intermediate layer being disposed at anangle to the fibers of the material of corresponding zones of layersabove and below it.

3. In combination in a multi-layer article, a plurality of superimposedlayers of fibrous material, each such layer having the fibers thereofdisposed in a plurality of generally parallel longitudinally extendingzones, the nbers of the material of each such zone being disposed at anangle to the fibers of the material of adjacent zones of said layer. andthe fibers of the material of each zone being disposed at an angle tothe fibers of the material of corresponding zones of layers next aboveand below it.

4. In combination in a composite article, a plurality of unfolded,lgenerally plane layers of fibrous material, said layers being disposedin a plurality of generally parallel, longitudinally extending zones,the material of each zone being disposed at an angle to the material ofadjacent zones of the layerwithin which it is disposed, and

' a plurality of generally. plane layers of folded,

fibrous material, at least one of said generally plane unfolded layersbeing positioned on the outside of said article, and at least one ofsaid folded layers being positioned inside said article with the foldlines at opposite sides thereof lying, respectively, in the planes ofthe opposed faces of said unfolded material.

5. In combination in a composite article, a

plurality of unfolded, generally plane layers of fibrous material. saidlayers `being disposed in a plurality of generally parallel,longitudinally ex-,

tending zones,

the material ofeach zone being disposed at an angle to the material ofadjacent zones of the layer within which it .is disposed,

and a plurality of generally plane layers of folded, fibrous material.at least one of said generally plane. unfolded layers being positionedonlr the outside of said article. and at least one of said folded layersbeing positioned inside said article, all of said layers being securedtogether with the fold lines at opposite sides thereof lying,respectively, in the planes unfolded material.

`8. In combination in a multi-layer article, a plurality of superimposedlayers of fibrous material, the nbers of the material of at least two ofsaid layers being disposed in a plurality of generally parallel,longitudinally extending zones, the fibrous materialof each such zonebeing disposed at an angle to zones of said layer, and the inbrous ofthe opposed faces of said the nbrous material of adjacent-y disposed atan angle to the fibrous material of.- adjacent zones of said layer, andthe fibrous material of each zone being disposed at an angle to thefibrous material of corresponding zones of layers above and below it, atleast one layer being generally plane, the fibers of which are generallyuniformly disposed and free of said longitudinal- 1y extending zones.

8. In combination in a composite article, a pair of unfolded, generallyplane layers of material, said layers being disposed in a plurality of'senerally parallel. longitudinally extending zones, the material of eachzone being disposed at an angle to the material of adjacent zones of thelayer within which it is disposed. and a layer of folded materialpositionedbetween and in contact with said layers of unfolded materialialongthe fold lines of said folded layer.

9. In combination in a composite article, a plurality of generallyplane, unfolded layers of material. said layers being disposed in aplurality of generally parallel, longitudinally extending zones, thematerial of each zone being disposed at an angle to the material ofadjacent zones of the layer within which it is disposed, and a pluy saidlayers of unfolded material along certain fold lines of said folded,layers and said two layers of folded material being in contact with eachother along certain other of said fold lines.

10. In combination ln a composite article, three layers of unfolded,generally plane material, said layers being disposed in a plurality ofgenerally parallel, longitudinally extending zones, the material of eachzone being disposed at an angle to the material of adjacent zones of thelayer with in which it lisdisposed. and two layers of folded material,two kof said unfolded layers being positioned on the outside of thecomposite article. and one unfolded layer being positioned within thearticle, each of said'folded layers being positioned between and incontact with two of said layers of unfolded material along the lines offold at 0pposite ends of the folded material.

The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 285,449 Newton Dec. 14, 1880735.821 Berr Apr. 21, 1908 1,100,084 Ferres June 10, 1914 1,405,185Cochran Jan. S1, 1922 v 1,585,257 Y Fowler Dec. 15, 1925 f 1,850,090Fowler May 24, 1932 1,995,158 Lormor s Sept. 12, 1983 2,104,060vSpafford Jan. 4, 1988 2,808,568 Rogers Jan. 19, 1943 2,419,971 Rumpf May8. 1947 Oct. 7. 1947 2,425,709 man

